Method for additively manufacturing a three-dimensional article

ABSTRACT

A method for additively manufacturing a three-dimensional article includes depositing feed materials through a material feeder to a growth surface. The feed materials include at least one of a first feed material, a second feed material and a third feed material. At least one of the first feed material, the second feed material and the third feed material is different. The method also includes exposing the feed materials to electromagnetic energy to form a melt pool. The melt pool includes at least one of a molten first feed material, a molten second feed material and a molten third feed material. The method further includes solidifying the melt pool.

PRIORITY

This application is a divisional of U.S. Ser. No. 14/679,201 filed onApr. 6, 2015.

FIELD

The present disclosure is generally related to additive manufacturingand, more particularly, to a deposition head for additive manufacturingcapable of depositing structurally different and/or compositionallydifferent feed materials.

BACKGROUND

Additive manufacturing, or “3D Printing,” is a manufacturing process inwhich an additive manufacturing system (e.g., a 3D printer) autonomouslyfabricates an object based on a three-dimensional model, or otherdigital representation, of a three-dimensional object. Additivemanufacturing systems fabricate, or print, the object by depositing, orotherwise forming, a constituent material in the shape of the objectuntil it is formed. In one common example, successive layers ofmaterial, that represent cross-sections of the object, are deposited andthe deposited layers of material are fused, or otherwise solidified, tobuild up the final object. The final three-dimensional object is fullydense and can include complex shapes.

A typical additive manufacturing process includes depositing a basematerial onto a growth surface (e.g., initially onto a substrate andlater onto a previously deposited layer of base material) and directingan energy source onto the growth surface to form a melt pool on thegrowth surface. The base material is deposited into and incorporated bythe melt pool to provide additional material to the objectlayer-by-layer.

One type of additive manufacturing process forms a large melt pooldeposition. Such a process may quickly create an object having a nearnet shape; however, this process requires post process machining toachieve the final three-dimensional shape of the object, effectivelyincreasing the time and cost to produce the object. Another type ofadditive manufacturing process forms a small melt pool deposition. Sucha process may allow for precise deposition to achieve the finalthree-dimensional shape of the object (e.g., only requiring finishingmachining); however, the process is slow and requires multiple passes toform the final object, effectively increasing the time and cost toproduce the object.

Accordingly, those skilled in the art continue with research anddevelopment efforts in the field of additive manufacturing ofthree-dimensional objects.

SUMMARY

In one embodiment, the disclosed deposition head for additivemanufacturing may include a material feeder including a first feeder todeposit a first feed material to a growth surface, and a second feederto deposit a second feed material to the growth surface, and anelectromagnetic energy source to direct electromagnetic energy to thegrowth surface, wherein the electromagnetic energy forms a melt pool onthe growth surface, and wherein the melt pool may include at least oneof a molten first feed material and a molten second feed material.

In another embodiment, the disclosed additive manufacturing apparatusmay include a build platform to support a growth surface, and adeposition head movable relative to the build platform, the depositionhead may include a first feeder to deposit a first feed material to thegrowth surface, and a second feeder to deposit a second feed material tothe growth surface, and an electromagnetic energy source to directelectromagnetic energy to the growth surface, wherein theelectromagnetic energy forms a melt pool on the growth surface, andwherein the melt pool may include at least one of a molten first feedmaterial and a molten second feed material.

In another embodiment, the disclosed method for additively manufacturinga three-dimensional article may include the steps of: (1) depositingfeed materials through a material feeder to a growth surface, whereinthe feed materials include at least one of a first feed material, asecond feed material and a third feed material, and wherein at least oneof the first feed material, the second feed material and the third feedmaterial is different, (2) exposing the feed materials toelectromagnetic energy to form a melt pool, wherein the melt poolincludes at least one of a molten first feed material, a molten secondfeed material and a molten third feed material, and (3) solidifying themelt pool.

In yet another embodiment, the disclosed method for additivelymanufacturing a three-dimensional article may include the steps of: (1)dispensing a powder feedstock through a powder guide formed in asidewall of a housing of a deposition head; (2) dispensing a wirefeedstock through a wire guide formed in the sidewall of the housing,separate from the powder guide; (3) positioning an optic, located withinthe housing, relative to a laser, located within the housing; and (4)heating a portion of at least one of the powder feedstock and the wirefeedstock using a laser beam, emitted by the laser and passing throughthe optic, to form a melt pool.

Other embodiments of the disclosed systems and method will becomeapparent from the following detailed description, the accompanyingdrawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is block diagram of one embodiment of the disclosed additivemanufacturing environment;

FIG. 2 is a schematic perspective view of one embodiment of thedisclosed additive manufacturing apparatus of FIG. 1;

FIG. 3 is a schematic side elevational view, in section, of oneembodiment of the disclosed deposition head for the additivemanufacturing apparatus of FIG. 1;

FIG. 4 is a schematic side elevational view, in section, of anotherembodiment of the disclosed deposition head;

FIG. 5 is another schematic side elevational view, in section, of thedeposition head of FIG. 4;

FIG. 6 is a schematic top plan view of one embodiment of a melt pool ona growth surface of the article of FIG. 1;

FIG. 7 is a flow diagram of one embodiment of the disclosed method foradditively manufacturing a three-dimensional article;

FIG. 8 is a block diagram of aircraft production and servicemethodology; and

FIG. 9 is a schematic illustration of an aircraft.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings,which illustrate specific embodiments of the disclosure. Otherembodiments having different structures and operations do not departfrom the scope of the present disclosure. Like reference numerals mayrefer to the same element or component in the different drawings.

Referring to FIG. 1, one embodiment of additive manufacturingenvironment, generally designated 100, is disclosed. Three-dimensionalarticle, generally designated “article” 102, may be manufactured byadditive manufacturing apparatus, generally designated “apparatus” 104.

As used herein, the term “article” refers to any three-dimensionalobject, workpiece, part, component, product or the like having almostany shape or geometry (e.g., complex shapes and/or geometries) andproduced by an additive manufacturing process. An additive manufacturingprocess includes any process or operation for manufacturing thethree-dimensional article in which successive layers of a base materialare laid down, for example, under computer control.

Referring to FIGS. 1 and 2, one embodiment of additive manufacturingapparatus 104 may include deposition head 106 and build platform 108.Article 102 may be supported on build platform 108 during fabrication.Build platform 108 may include a base plate, a substrate or any othersuitable build surface to support layers of feed materials 118 andarticle 102, additively manufactured thereon. Deposition head 106 mayinclude material feeder 110. Material feeder 110 may be configured todeposit one or more feed materials 118 (e.g., a plurality of differenttypes of base materials) to form growth surface 120. Deposition head 106may include electromagnetic energy source 112. Electromagnetic energysource 112 may generate and/or emit electromagnetic energy 114 capableof irradiating feed materials 118 to form a localized melt pool 124 ongrowth surface 120. Article 102 may be manufactured by successiveaddition of layers 122 of feed materials 118 having a predeterminedthickness t, area a, and/or contour c (FIG. 1), which are melted byelectromagnetic energy 114 directed to growth surface 120 fromelectromagnetic energy source 112.

Electromagnetic energy 114 may include a concentrated beam of directedelectromagnetic radiation or energy (e.g., an energy beam for energyirradiation or a laser beam for laser irradiation). As one general,non-limiting example, electromagnetic energy source 112 may includelaser 126 (e.g., a laser beam generator). Laser 126 may generate and/oremit laser beam 128 (e.g., electromagnetic energy 114) capable ofselectively melting feed materials 118. As one specific, non-limitingexample, laser 126 may include a fiber laser, for example, a 5 kW fiberlaser. As another general, non-limiting example, electromagnetic energysource 112 may include an electron beam generator (not explicitlyillustrated) configured to generate and/or emit an electron beam (e.g.,electromagnetic energy 114) capable of selectively melting feedmaterials 118.

As one example, the additive manufacturing technique disclosed herein(e.g., apparatus 104 and/or method 300) may be selective laser melting(“SLM”). As another example, the additive manufacturing techniquedisclosed herein (e.g., apparatus 104 and/or method 300) may beselective laser sintering (“SLS”). As another example, the additivemanufacturing technique disclosed herein (e.g., apparatus 104 and/ormethod 300) may be electron beam melting (“EBM”).

Referring to FIG. 2, and with reference to FIG. 1, as one example, oneor more feed materials 118 may initially be deposited, from materialfeeder 110, on a surface of build platform 108 to form growth surface120. Electromagnetic energy 114 may be directed at feed materials 118,for example, at a selected location on build platform 108, to form meltpool 124 (e.g., a molten puddle of feed materials 118) on growth surface120. Subsequent layers of one or more feed materials 118 may bedeposited onto the previously grown (e.g., built up) material layer andintegrated within melt pool 124 (e.g., by melting and forming a solutionwithin melt pool 124) on growth surface 120. Introduction of additionalfeed materials 118 may force a portion of the original melt pool 124 tosolidify (e.g., cool) at a melt pool-growth surface interface, therebyforming a new material layer and building up growth surface 120.

Referring to FIG. 2, deposition head 106 may be movable relative togrowth surface 120 (e.g., article 102 or build platform 108), forexample, during fabrication of article 102. Movement of deposition head106 relative to growth surface 120 may facilitate successive layering offeed materials 118 and/or appropriately deposit feed material 118,position electromagnetic energy 114 and/or move the location of meltpool 124 on growth surface 120.

As one example, deposition head 106 may be linearly movable to growthsurface 120. For instance, deposition head 106 may be linearly movedalong an X-axis, a Y-axis, a Z-axis or a combination thereof. As anotherexample, deposition head 106 may be rotatably moveable relative togrowth surface 120. For instance, deposition head 106 may be rotatablymoved about the X-axis, the Y-axis, the Z-axis or a combination thereof.As yet another example, deposition head 106 may be non-linearly movablerelative to growth surface 120. For instance, deposition head 106 may befreely moved relative to growth surface 120, for example, to formarticle 102 having complex shapes.

Apparatus 104 may include deposition head drive mechanism 130.Deposition head drive mechanism 130 may be operatively coupled todeposition head 106. As general, non-limiting examples, deposition headdrive mechanism 130 may include any suitable mechanical,electro-mechanical, hydraulic or pneumatic mechanism configured to drivemotion (e.g., linear, rotatable, and/or non-linear) of deposition head106 relative to article 102 (e.g., relative to growth surface 120). Asother general, non-limiting examples, deposition head drive mechanism130 may include robotic mechanisms, end-effectors, autonomous vehiclesand/or other related technologies configured to drive motion ofelectromagnetic radiation source 112 relative to article 102.

In addition to, or alternatively, build platform 108 may be movablerelative to deposition head 106, for example, during fabrication ofarticle 102. Movement of build platform 108 relative to deposition head106 may facilitate successive layering of feed materials 118 and/orappropriately position growth surface 120, for example, to deposit feedmaterials 118, to locate the directed electromagnetic energy 114 and/ormove the location of melt pool 124.

As one example, build platform 108 may be linearly movable, for example,relative to deposition head 106. For instance, build platform 108 may belinearly moved along the X-axis, the Y-axis, the Z-axis or a combinationthereof. As another example, build platform 108 may be rotatablymoveable, for example, relative to deposition head 106. For instance,build platform 108 may be rotatably moved about the X-axis, the Y-axis,the Z-axis or a combination thereof. As yet another example, buildplatform 108 may be non-linearly movable, for example, relative todeposition head 106. For instance, build platform 108 may be freelymoved relative to deposition head 106.

Apparatus 104 may include build platform drive mechanism 132. Buildplatform driving mechanism 132 may be operatively coupled to buildplatform 108. As general, non-limiting examples, build platform drivingmechanism 132 may include any suitable mechanical, electro-mechanical,hydraulic or pneumatic mechanism configured to drive motion (e.g.,linear, rotatable and/or non-linear) of build platform 108 relative todeposition head 106. As other general, non-limiting examples, buildplatform drive mechanism 132 may include robotic mechanisms,end-effectors, autonomous vehicles and/or other related technologiesconfigured to drive motion of build platform 108.

Referring to FIG. 3, and with reference to FIG. 1, in one embodiment ofdeposition head 106, material feeder 110 may include first feeder 134and second feeder 136. First feeder 134 may be configured to selectivelydeposit first feed material 140 to growth surface 120 (e.g., introducefirst feed material 140 to melt pool 124). Second feeder 136 may beconfigured to selectively deposit second feed material 142 to growthsurface 120 (e.g., introduce second feed material 142 to melt pool 124).

Unless otherwise indicated, the terms “first,” “second,” “third,” etc.are used herein merely as labels, and are not intended to imposeordinal, positional, or hierarchical requirements on the items to whichthese terms refer. Moreover, reference to a “second” item does notrequire or preclude the existence of lower-numbered item (e.g., a“first” item) and/or a higher-numbered item (e.g., a “third” item).

In one example implementation, first feed material 140 and second feedmaterial 142 may be different. As one general, non-limiting example,first feed material 140 and second feed material 142 may be structurallydifferent. As one specific, non-limiting example, first feed material140 may include powder 164 (e.g., metal powder) and second feed material142 may include wire 166 (e.g., solid metal wire). As one example, metalpowder 164 and/or metal wire 166 may be a pure metallic material havingno additional filler materials. As another example, metal powder 164and/or metal wire 166 may include additional materials

As another general, non-limiting example, first feed material 140 andsecond feed material 142 may be compositionally different. As anotherspecific, non-limiting example, first feed material 140 may includefirst constituent material 168 and second feed material 142 may includesecond constituent material 170 (FIG. 1). First constituent material 168and second constituent material 170 may be different. As general,non-limiting examples, first constituent material 168 and/or secondconstituent material 170 may be metal or metal alloy. As specific,non-limiting examples, first constituent material 168 may include steel,aluminum, titanium, nickel or any suitable refractory metal and/or anyalloys based from steel, aluminum, titanium, nickel or any suitablerefractory metal. As specific, non-limiting examples, second constituentmaterial 170 may include steel, aluminum, titanium, nickel or anysuitable refractory metal and/or any alloys based from steel, aluminum,titanium, nickel or any suitable refractory metal.

In yet another general, non-limiting example, first feed material 140and second feed material 142 may be structurally and compositionallydifferent. As yet another specific, non-limiting example, first feedmaterial 140 may include powder 164 including first constituent material168 (e.g., steel powder) and second feed material 142 may include wire166 including second constituent material 170 (e.g., nickel wire).

Referring to FIG. 4, and with reference to FIG. 1, in one embodiment ofdeposition head 106, material feeder 110 may further include thirdfeeder 138 (e.g., material feeder 110 may include first feeder 134,second feeder 136 and third feeder 138). Third feeder 138 may beconfigured to selectively deposit third feed material 144 to growthsurface 120 (e.g., introduce third feed material 144 to melt pool 124).

In one example implementation, at least one of first feed material 140,second feed material 142 and/or third feed material 144 may bedifferent. As one general, non-limiting example, first feed material140, second feed material 142 and/or third feed material 144 may bestructurally different. As one specific, non-limiting example, firstfeed material 140 may include powder 164 (e.g., metal powder), secondfeed material 142 may include wire 166 (e.g., solid metal wire) andthird feed material 144 may include wire 166 (e.g., solid metal wire).As another specific, non-limiting example, second feed material 142 mayinclude wire 166 (e.g., first wire 166 a) (FIG. 4) having a firstdiameter d1 and third feed material 144 may include wire 166 (e.g.,second wire 166 b) (FIG. 4) having a second diameter d2. The firstdiameter d1 and the second diameter d2 may be different. For example,the first diameter d1 of first wire 166 a (e.g., second feed material142) may be a large diameter and the second diameter d2 of second wire166 b (e.g., third feed material 144) may be a small diameter (e.g., thefirst diameter d1 may be larger than the second diameter d2). As onenon-limiting example, a large diameter may include approximately 0.375inch. As one non-limiting example, a small diameter may includeapproximately 0.100 inch. Other diameters of metal wire 166 are alsocontemplated.

As used herein “at least one of” means any combination of singleelements or any combination of multiple elements. For example, at leastone of X, Y and/or Z may mean X, Y, Z, X and Y, X and Z, Y and Z, or Xand Y and Z.

As another general, non-limiting example, at least one of first feedmaterial 140, second feed material 142 and/or third feed material 144may be compositionally different. As another specific, non-limitingexample, first feed material 140 may include first constituent material168, second feed material 142 may include second constituent material170 and third feed material 144 may include third constituent material172 (FIG. 1). At least one of first constituent material 168, secondconstituent material 170 and/or third constituent material 172 may bedifferent. As general, non-limiting examples, first constituent material168, second constituent material 170 and/or third constituent material172 may be metal or metal alloy. As specific, non-limiting examples,third constituent material 172 may include steel, aluminum, titanium,nickel or any suitable refractory metal and/or any alloys based fromsteel, aluminum, titanium, nickel or any suitable refractory metal.

In yet another general, non-limiting example, at least one of first feedmaterial 140, second feed material 142 and/or third feed material 144may be structurally and compositionally different. As yet anotherspecific, non-limiting example, first feed material 140 may include,e.g., metal, powder 164 (e.g., metal powder) including first constituentmaterial 168, second feed material 142 may include, e.g., metal, wire166 (e.g., first wire 166 a) having a first diameter d1 and includingsecond constituent material 170, and third feed material 144 mayinclude, e.g., metal, wire 166 (e.g., second wire 166 b) having a seconddiameter d2 and including third constituent material 172. As oneexample, at least one of first constituent material 168, secondconstituent material 170 and/or third constituent material 172 may bedifferent. As another example, the first diameter d1 and the seconddiameter d2 may be different. As yet another example, at least one offirst constituent material 168, second constituent material 170 and/orthird constituent material 172 may be different and the first diameterd1 and the second diameter d2 may be different.

One advantage of introducing different feed materials 118 (e.g., firstfeed material 140, second feed material 142 and/or third feed material144) having different structural characteristics is, for example, theability to increase the flexibility of the type of structural component174 being formed. As example, wire 166 (e.g., second feed material 142)having a large diameter d1 may be deposited on growth surface 120 toform a large structural component 174 (e.g., a bulk structure). Asanother example, wire 166 (e.g., third feed material 144) having a smalldiameter d2 may be deposited on growth surface 120 to form a smallstructural component 174 (e.g., a detailed structure). As anotherexample, powder 164 (e.g., first feed material 140) may be deposited ongrowth surface 120 to form a fine structural component 174 (e.g., a finestructural detail).

One advantage of introducing different feed materials 118 (e.g., firstfeed material 140, second feed material 142 and/or third feed material144) having different compositional characteristics is, for example, theability to create one or more particular alloys (e.g., materialscomposed of two or more metals or a metal and a nonmetal) or superalloys(e.g., a high performance-alloy). As one example, introducing first feedmaterial 140 (e.g., powder 164) of first constituent material 168 (e.g.Titanium) and second feed material 142 (e.g., wire 166) of secondconstituent material 170 (e.g., Aluminum) into melt pool 124 may mixmolten first feed material 146 and molten second feed material 148 toform a particular alloy (e.g., Titanium Aluminide (TiAl)).

As another example, introducing first feed material 140 (e.g., powder164) of first constituent material 168 (e.g., commercially pureTitanium), second feed material 142 (wire 166) of second constituentmaterial 170 (e.g., Aluminum) and third feed material 144 (wire 166) ofthird constituent material 172 (e.g., Vanadium) into melt pool 124 maymix molten first feed material 146, molten second feed material 148 andmolten third feed material 150 to form a particular alloy (e.g.,Ti6Al-4V).

Another advantage of introducing different feed materials 118 (e.g.,first feed material 140, second feed material 142 and/or third feedmaterial 144) having different compositional characteristics is, forexample, the ability to create article 102 including multiple differentmetals and/or different alloys. For example, one or more built-up layers122 of article 102 or certain portions of article 102 may includedifferent metals, different alloys or a combination thereof.

One or more feed materials 118 (e.g., at least one of first feedmaterial 140, second feed material 142 and/or third feed material 144)may be deposited on growth surface 120 (e.g., introduced into melt pool124) at different feed rates. As used herein, the term “feed rate”generally refers to the amount of the feed material being deposited onthe growth surface, for example, based on the volume of the feedmaterial and the introduction speed of the feed material (e.g., volumeas a function of time). Further, the feed rates of feed materials 118may be modified or adjusted during fabrication of article 102. The feedrate of different feed materials 118 may be dictated by, for example, aspot size of electromagnetic energy 114 (e.g., spot size of laser beam128) on growth surface 120, the dimension D of melt pool 124, theparticular structural features 174 being formed, the power level ofelectromagnetic energy source 112 (e.g., the wattage of laser 126), theconstituent materials of feed materials 118 (e.g., first constituentmaterial 168, second constituent material 170 and/or third constituentmaterial 172) and the like.

One advantage of varying the feed rate of feed materials 118 duringfabrication of article 102 is, for example, the ability to build-upvarious structural features 174 of article 102, one or more structuralfeatures 174 having a different level of complexity (e.g., size, shape,detail, etc.), in order to maximize the throughput rate of differentfeed materials 118 and minimize the fabrication time of article 102.

One advantage of introducing different feed materials 118 (e.g., firstfeed material 140, second feed material 142 and/or third feed material144) having different compositional characteristics (e.g., differentconstituent materials) and at different feed rates is, for example, theability to transition from one constituent material to a differentconstituent material within article 102 (e.g., from one layer 122 toanother layer 122) during fabrication of article 102. For example, oneor more of first feed material 140, second feed material 142 and/orthird feed material 144 may be used to form a particular (e.g., desired)metal or metal alloy at growth surface 120 (e.g., melt pool 124 mayinclude one or more of molten first feed material 146, molten secondfeed material 148 and/or molten third feed material 150). During thebuild-up of article 102 (e.g., during formation of a successive layer122), the amount (e.g., feed rate) of at least one of feed materials 118(e.g., second feed material 142) may be varied (e.g., increased orreduced) to create a material transition (e.g., functionally gradedtransitions) within article 102 during fabrication of article 102. Asone non-limiting example, article 102 may transition (e.g., throughsuccessive layers 122) from stainless steel to Inconel (e.g., a familyof austenite nickel-chromium-based superalloys) by changing the feedrate of different feed materials 118 to form a functionally gradedarticle.

Another advantage of introducing different feed materials 118 (e.g.,first feed material 140, second feed material 142 and/or third feedmaterial 144) having different compositional characteristics (e.g.,different constituent materials) and at different feed rates is, forexample, a significant reduction in waste of feed materials 118resulting from mixing constituent materials to form a desired alloy. Forexample, excess powder 164 may not be contaminated by mixing differentconstituent materials in order to create the desired alloy since thealloy mixing is performed on growth surface 120 (e.g., within melt pool124).

Referring to FIGS. 3 and 4, and with reference to FIG. 1, depositionhead 106 may include optic 160. Optic 160 may be located betweenelectromagnetic energy source 112 and article 102 (e.g., growth surface120 of article 102). Optic 160 may include any suitable beam formingoptics. As one non-limiting example, optic 160 may include precisionground optical glass. As another non-limiting example, optic 160 mayinclude any refractory optical system.

Optic 160 may be configured to form, size and/or shape electromagneticenergy 114 (e.g., laser beam 128), for example, on growth surface 120.For example, optic 160 may at least partially dictate the size and/orshape of electromagnetic energy 114 at growth surface 120. As oneexample, optic 160 may control the spot shape (e.g., geometry) ofelectromagnetic energy 114 (e.g., the spot shape of laser beam 128) ongrowth surface. As non-limiting examples, the spot shape ofelectromagnetic energy 114 (e.g., laser beam 128) on growth surface mayinclude circular, ovular, square, or rectangular. Other geometric shapesare also contemplated. As another example, optic 160 may control thespot size (e.g., diameter of a circular spot, an inner linear dimensionof a square spot, etc.) of electromagnetic energy 114 (e.g., the spotsize of laser beam 128) on growth surface 120.

Those skilled in the art will recognize that the power level ofelectromagnetic energy source 112 (e.g., the wattage of laser 126) mayalso at least partially dictate the size and/or shape of electromagneticenergy 114 at growth surface 120.

Accordingly, optic 160 may at least partially dictate the size and/orshape of melt pool 124. Those skilled in the art will recognize that thepower level of electromagnetic energy source 112 (e.g., the wattage oflaser 126) may also at least partially dictate the size and/or shape ofmelt pool 124.

Referring to FIG. 6, and with reference to FIG. 1, melt pool 124 maydefine a portion of growth surface 120 to which feed materials 118 arebeing added in order to build up article 102 (e.g., form a layer 122).Melt pool 124 may include at least one of molten first feed material 146(e.g., first feed material 140 melted by the directed electromagneticenergy 114), molten second feed material 148 (e.g., second feed material142 melted by the directed electromagnetic energy 114) and/or moltenthird feed material 150 (e.g., third feed material 144 melted by thedirected electromagnetic energy 114). Melt pool 124 may include a sizeand/or a shape. The size and/or shape of melt pool 124 may be at leastpartially dictated by the size and/or shape of the directedelectromagnetic energy 114 (e.g., laser beam 128) at growth surface 120.

As one non-limiting example, and as illustrated in FIG. 6, the shape ofmelt pool 124 may circular. As other non-limiting examples (notexplicitly illustrated), the shape of the melt pool 124 may includesquare, rectangular or ovular. Other geometric shapes of melt pool 124are also contemplated. The shape of melt pool 124 may be at leastpartially dictated by the shape of electromagnetic energy 114 (e.g.,laser beam 128) at growth surface 120, for example, as controlled byoptic 160.

Melt pool 124 may include a size generally corresponding to the size ofelectromagnetic energy 114 (e.g., laser beam 128) at growth surface 120,for example, as controlled by optic 160. Melt pool 124 may include adimension D. As one example, the dimension D may be the diameter betweenouter perimeter edges of a circular melt pool 124, as illustrated inFIG. 6. As another example, the dimension D may be the linear distance(e.g., a major dimension or a minor dimension) between outer perimeteredges of a square, rectangular or ovular melt pool 124.

Referring to FIG. 5, optic 160 may be movable relative toelectromagnetic energy source 112. As one example, optic 160 may belinearly movable along the Z-axis (FIG. 2), in the direction indicatedby arrow 200, as illustrated in FIGS. 4 and 5. As other examples, optic160 may be also be linearly movable along at least one of the X-axisand/or the Y-axis, a Z-axis, rotatably moveable about at least one ofthe X-axis, the Y-axis and/or the Z-axis, and/or non-linearly movable.Movement of optic 160 relative to electromagnetic energy source 112 maytransform, resize and/or reshape electromagnetic energy 114 (e.g., laserbeam 128).

Referring to FIG. 3-6, movement of optic 160 (e.g., changing thelocation of optic 160 relative to electromagnetic energy source 112 orgrowth surface 120) (FIGS. 3-5) may adjust the size and/or shape of meltpool 124 (FIG. 6) during fabrication of article 102 or fabrication of aparticular structural feature 174 of article 102. As example, with optic160 in a first position, such as the position illustrated in FIGS. 3 and4, electromagnetic energy source 112 may direct electromagnetic energy114 (e.g., laser beam 128) (FIG. 1) having a large spot size and, thus,forming a large melt pool 124, as illustrated in broken lines in FIG. 6.As another example, with optic 160 in a second position, such as theposition illustrated in FIG. 5, electromagnetic energy source 112 maydirect electromagnetic energy 114 (e.g., laser beam 128) (FIG. 1) havinga small spot size and, thus, forming a small melt pool 124, asillustrated in solid lines in FIG. 6.

As one non-limiting example, a large melt pool 124 may include adimension D of at least approximately 0.375 inch. As anothernon-limiting example, a large melt pool 124 may include a dimension D ofapproximately 0.375 inch. As another non-limiting example, a large meltpool 124 may include a dimension D of more than 0.375 inch. As onenon-limiting example, a small melt pool 124 may include a dimension D ofat least approximately 0.070 inch. As another non-limiting example, asmall melt pool 124 may include a dimension D of approximately 0.070inch. As another non-limiting example, a small melt pool 124 may includea dimension D of more than 0.070 inch.

One advantage of adjusting the size and/or shape of electromagneticenergy 114 at growth surface 120 and, thus, adjusting the size and/orshape of melt pool 124 is, for example, the ability to tailor the sizeand/or shape of melt pool 124 to fabricate both large (e.g., bulk)structural features 174 and small (e.g., detailed) structural features174 during the same additive manufacturing process (e.g., using the samedeposition head 106 and/or apparatus 104) without sacrificing depositionthroughput. As one example, a large melt pool 124 may accommodate alarger amount of feed materials 118 to form large structural features174. As another example, a small melt pool 124 may accommodate a smalleramount of feed materials 118 to form fine structural features 174.

Referring to FIG. 3-5, and with reference to FIG. 1, deposition head 106may include optic drive mechanisms 162. Optic drive mechanism 162 may beoperatively coupled to optic 160. As general, non-limiting examples,optic drive mechanism 162 may include any suitable mechanical,electro-mechanical, hydraulic or pneumatic mechanism configured to drivemotion (e.g., linear, rotatable, and/or non-linear) of optic 160relative to electromagnetic energy source 112 (and relative to growthsurface 120). As specific, non-limiting examples, optic drive mechanism162 may include a linear drive motor, a worm gear, a belt drive and thelike.

Alternatively, optic 160 may be fixed relative to electromagnetic energysource 112 in order to fix the form, size and/or shape ofelectromagnetic energy 114 (e.g., laser beam 128) at growth surface 120.Optionally, electromagnetic energy source 112 may be linearly movablerelative to optic 160 in order to adjust the form, size and/or shape ofelectromagnetic energy 114 (e.g., laser beam 128) at growth surface 120.

Optionally (e.g., if needed based on potential overheating of optic160), deposition head 106 may include a cooling mechanism (not shown)associated with optic 160.

Referring to FIGS. 1 and 2, apparatus 104 may include source 152 of feedmaterials 118. Source 152 may include any suitable repository forstoring one or more feed materials 118 to be used by deposition head 106during fabrication of article 102. For example, source 152 may includeat least one of first source 154 of first feed material 140, secondsource 156 of second feed material 142 and/or third source 158 of thirdfeed material 144. As a non-limiting example, first source 154 may storea supply of powder 164, for example, of first constituent material 168.As another non-limiting example, second source 156 may store a supply ofwire 166, for example, of second constituent material 170 and/or havingthe first diameter d1. As another non-limiting example, third source 158may store a supply of wire 166, for example, of third constituentmaterial 172 and/or having the second diameter d2.

While the example of FIG. 1 illustrates three sources of feed materials,additional numbers of sources are contemplated depending upon, forexample, the number of different types of feed materials being used tofabricate the article by the additive manufacturing techniques describedherein. As one example, apparatus 104 may include a suitable number ofsources 152 to supply the any suitable number of various structurallyand/or compositionally different feed materials 118 used to fabricatearticle 102.

Apparatus 104 may include delivery mechanism 178. Delivery mechanism 178may deliver, transfer or distribute feed materials 118 to depositionhead 106, for example, from source 152 to material feeder 110. Forexample, delivery mechanism 178 may include at least one of firstdelivery mechanism 180 to deliver first feed material 140 from firstsource 154 to first feeder 134, second delivery mechanism 182 to deliversecond feed material 142 from second source 156 to second feeder 136and/or third delivery mechanism 184 to deliver third feed material 144from third source 158 to third feeder 138. As a non-limiting example,first delivery mechanism 180 may be configured to transfer powder 164from first source 154 directly to first feeder 134. As specific,non-limiting examples, first delivery mechanism 180 may be a materialauger, a hopper, a pneumatic powder delivery mechanism or other suitablepowdered material delivery device. As another, non-limiting example,second delivery mechanism 182 may be configured to transfer wire 166(e.g., first wire 166 a having the first diameter d1) from second source156 directly to second feeder 136. As another, non-limiting example,third delivery mechanism 184 may be configured to transfer wire 166(e.g., second wire 166 b having the second diameter d2) from thirdsource 158 directly to third feeder 138. As specific, non-limitingexamples, second delivery mechanism 182 and/or third delivery mechanism184 may be a pinch roller, a wire feeder, a pneumatic wire deliverymechanism or other suitable wire delivery device. Second deliverymechanism 182 and/or third delivery mechanism 184 may also include awire straightener (not shown).

First delivery mechanism 180 may be configured to accommodate a desiredfeed rate of first feed material 140. First delivery mechanism 180 maybe further be configured to adjust the desired feed rate of first feedmaterial 140. As one non-limiting example, first delivery mechanism 180may deliver first feed material 140 (e.g., powder 164) at a rate ofapproximately 6 g/min. Second delivery mechanism 182 may be configuredto accommodate a desired feed rate of second feed material 142. Seconddelivery mechanism 182 may be further be configured to adjust thedesired feed rate of second feed material 142. As one non-limitingexample, second delivery mechanism 182 may deliver second feed material142 (e.g., wire 166) at a rate of approximately 2 in/min. Third deliverymechanism 184 may be configured to accommodate a desired feed rate ofthird feed material 144. Third delivery mechanism 184 may be further beconfigured to adjust the desired feed rate of third feed material 144.As one non-limiting example, third delivery mechanism 184 may deliverthird feed material 144 (e.g., powder 164) at a rate of approximately 5in/min. Other feed rates for one or more of first feed material 140,second feed material 142 and/or third feed material 144 are alsocontemplated.

Referring to FIGS. 1 and 2, apparatus 104 may include control unit 176.Control unit 176 may be communication with and configured to controldeposition head 106 and build platform 108 during fabrication of article102. As one example, control unit 176 may be in communication withelectromagnetic energy source 112 (e.g., laser beam 128) to initiate andcease emission of electromagnetic energy 114, control the power level ofelectromagnetic energy source 112 and the like. As another example,control unit 176 may be in communication with deposition head drivemechanism 130 and/or built platform drive mechanism 132 to control theposition and/or movement of deposition head 106 and/or build platform108. As another example, control unit 176 may be in communication withoptic drive mechanism 162 to control the position and/or movement ofoptic 160. As another example, control unit 176 may be in communicationwith delivery mechanism 178 (e.g., first delivery mechanism 180, seconddelivery mechanism 182 and/or third delivery mechanism 184) to controlthe delivery and/or the feed rate of feed materials 118 (e.g., firstfeed material 140, second feed material 142 and/or third feed material144) to material feeder 110 (e.g., first feeder 134, second feeder 136and/or third feeder 138) during fabrication of article 102.

Referring to FIGS. 3-5, deposition head 106 may include an exteriorhousing 186. Housing 186 may enclose electromagnetic energy source 112,optic 160 and/or optic drive mechanism 162, for example, within an openinterior region 252. As one example, housing 186 may define a nozzlebody 188 and include first (e.g., upper) end 190 and second (e.g.,lower) end 192 opposite first end 190. Housing 186 may be open at secondend 192 for deposition of feed materials 118. Electromagnetic energy 114may exit housing 186 through second end 192.

Nozzle body 188 may define material feeder 110. Feed materials 118 mayenter nozzle body 188 at first end 190 and exit at second end 192 fordeposition on growth surface 120 (e.g., introduction to melt pool 124).First feeder 134 may include first guide 194 formed within a sidewall250 forming nozzle body 188. First guide 194 may include, for example, achannel, tube or the like formed through (e.g., extending through)nozzle body 188 from first end 190 to second end 192 of housing 186.First guide 194 may be configured to allow passage of first feedmaterial 140 through nozzle body 188 to growth surface 120. For example,first guide 194 may be configured to allow passage of powder 164. Secondfeeder 136 may include second guide 196 formed within the sidewall 250forming nozzle body 188. Second guide 196 may include, for example, achannel, tube or the like formed through (e.g., extending through)nozzle body 188 from first end 190 to second end 192 of housing 186.Second guide 196 may be configured to allow passage of second feedmaterial 142 through nozzle body 188 to growth surface 120. For example,second guide 196 may be configured to allow passage of wire 166, forexample, having the first diameter d1 (e.g., first wire 166 a) (FIGS. 4and 5). Similarly, third feeder 138 may include third guide 198 formedwithin the sidewall 250 forming nozzle body 188. Third guide 198 mayinclude, for example, a channel, tube or the like formed through (e.g.,extending through) nozzle body 188 from first end 190 to second end 192of housing 186. Third guide 198 may be configured to allow passage ofthird feed material 144 through nozzle body 188 to growth surface 120.For example, third guide 198 may be configured to allow passage of wire166, for example, having the second diameter d2 (e.g., second wire 166b) (FIGS. 4 and 5).

The deposition angle (not explicitly illustrated) of feed materials 118(e.g., one or more of first feed material 140, second feed material 142and/or third feed material 144) on growth surface 120 (e.g., the angleof introduction into melt pool 124) may affect one or morecharacteristics of melt pool 124. For example, the deposition angle mayaffect the quality of the weld puddle (e.g., one or more of molten firstfeed material 146, molten second feed material 148 and/or molten thirdfeed material 150). The deposition angle of feed materials 118 may becontrolled by or at least partially dictated by, for example, thestructural configuration of deposition head 106 (e.g., the configurationof nozzle body 188), the orientation of deposition head 106 (e.g., theorientation of second end 192 of nozzle body 188) relative to growthsurface 120 and/or melt pool 124 and the like.

Referring to FIG. 7, one embodiment of method, generally designated 300is disclosed. Modifications, additions, or omissions may be made tomethod 300 without departing from the scope of the present disclosure.Method 300 may include more, fewer, or other steps. Additionally, stepsmay be performed in any suitable order.

Referring to FIG. 7, and with reference to FIG. 1, method 300 mayinclude the step of depositing feed materials 118 through materialfeeder 110 on growth surface 120, as shown at block 302. As one example,feed materials 118 may include at least one of first feed material 140,second feed material 142 and/or third feed material 144. At least one offirst feed material 140, second feed material 142 and third feedmaterial 144 may be different. As one example, at least one of firstfeed material 140, second feed material 142 and third feed material 144may be structurally different. As another example, at least one of firstfeed material 140, second feed material 142 and third feed material 144may be compositionally different. As yet another example, at least oneof first feed material 140, second feed material 142 and third feedmaterial 144 may be structurally different and compositionallydifferent.

Method 300 may include the step of exposing feed materials 118 toelectromagnetic energy 114 to form melt pool 124, as shown at block 304.Melt pool 124 may include at least one of a molten first feed material146, a molten second feed material 148 and a molten third feed material150. Melt pool 124 may be located at a predetermined location on growthsurface 120.

Method 300 may include the step of solidifying melt pool 124, as shownat block 306. Solidification of melt pool 124 may form at least aportion of layer 122 of article 102.

Method 300 may include the step of adjusting a size of melt pool 124, asshown at block 308. As one example, the size of melt pool 124 (e.g., thedimension D of melt pool 124) (FIG. 6) may be adjusted by moving optic160 relative to electromagnetic energy source 112 (e.g., laser 126)and/or growth surface 120 to modify the size (e.g., spot size) ofelectromagnetic energy 114 (e.g., laser beam 128) on growth surface 120.As another example, the size of melt pool 124 may be adjusted byadjusting (e.g., modifying) one or more operational parameters ofdeposition head 106. As one example, the size of melt pool 124 may beadjusted by changing (e.g., increasing or decreasing) the power level ofelectromagnetic energy source 112. As another example, the size of meltpool 124 may be adjusted by changing the feed rate (e.g., increasing ordecreasing) of feed materials 118 (e.g., at least one of first feedmaterial 140, second feed material 142 and/or third feed material 144).

The steps shown at blocks 302, 304, 306 and/or 308 may be repeated atone or more different locations on growth surface 120 to build upstructural feature 174 of article 102. Article 102 and/or structuralfeatures 174 of article 102 may be formed by a plurality of layers 122.As one example, article 102 may be built up layer-by-layer, generallyalong the Z-axis (e.g., orthogonal to an X-Y plane of growth surface120) (FIG. 2).

Examples of the present disclosure may be described in the context ofaircraft manufacturing and service method 1100 as shown in FIG. 8 andaircraft 1200 as shown in FIG. 9. During pre-production, theillustrative method 1100 may include specification and design, as shownat block 1102, of aircraft 1200 and material procurement, as shown atblock 1104. During production, component and subassembly manufacturing,as shown at block 1106, and system integration, as shown at block 1108,of aircraft 1200 may take place. Thereafter, aircraft 1200 may gothrough certification and delivery, as shown block 1110, to be placed inservice, as shown at block 1112. While in service, aircraft 1200 may bescheduled for routine maintenance and service, as shown at block 1114.Routine maintenance and service may include modification,reconfiguration, refurbishment, etc. of one or more systems of aircraft1200.

Each of the processes of illustrative method 1100 may be performed orcarried out by a system integrator, a third party, and/or an operator(e.g., a customer). For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 9, aircraft 1200 produced by illustrative method 1100may include airframe 1202 with a plurality of high-level systems 1204and interior 1206. Examples of high-level systems 1204 include one ormore of propulsion system 1208, electrical system 1210, hydraulic system1212 and environmental system 1214. Any number of other systems may beincluded. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive and marine industries.

The apparatus and methods shown or described herein may be employedduring any one or more of the stages of the manufacturing and servicemethod 1100. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing (block 1106) may be fabricatedor manufactured in a manner similar to components or subassembliesproduced while aircraft 1200 is in service (block 1112). Also, one ormore examples of the apparatus and methods, or combination thereof maybe utilized during production stages (blocks 1108 and 1110), forexample, by substantially reducing the risks associated with counterfeitcomponents in aircraft manufacturing and service processes. Similarly,one or more examples of the apparatus and methods, or a combinationthereof, may be utilized, for example and without limitation, whileaircraft 1200 is in service (block 1112) and during maintenance andservice stage (block 1114).

Thus, the various embodiments of additive manufacturing apparatus 104,deposition head 106 for additive manufacturing and method 300 disclosedherein may utilize and deposit multiple types of feed materials 118(e.g., feedstock) to influence the fabrication rate of the additivemanufacturing process. One or more feed materials 118 (e.g., first feedmaterial 140, second feed material 142, third feed material 144, etc.)may be structurally different (e.g., including powder, wire or differentdiameters of wire), compositionally different (e.g., including differentconstituent materials) or a combination of structurally andcompositionally different. This will allow the build up (e.g.,fabrication) of both fine and large structural features 174 by tailoringthe type and amount of feed materials 118 without sacrificing depositionthroughput and reducing post-process machining of a three-dimensionalarticle 102 fabricated by the additive manufacturing process. This willalso allow simultaneous use of different material types (e.g., alloys)to achieve a functionally graded transition throughout article 102.

Although various embodiments of the disclosed apparatus and methods havebeen shown and described, modifications may occur to those skilled inthe art upon reading the specification. The present application includessuch modifications and is limited only by the scope of the claims.

What is claimed is:
 1. A method for additively manufacturing athree-dimensional article, said method comprising: depositing a powderfeedstock through a powder guide of a deposition head on a growthsurface in a powdered form; depositing a continuous wire feedstockthrough a wire guide of said deposition head on said growth surface in asolid form; exposing at least one of said powder feedstock and saidcontinuous wire feedstock to electromagnetic energy at said growthsurface to form a melt pool on said growth surface, wherein said meltpool comprises at least one of said powder feedstock in a molten formand said continuous wire feedstock in a molten form; solidifying saidmelt pool; depositing a second continuous wire feedstock through asecond wire guide of said deposition head on said growth surface in asolid form; and exposing at least one of said powder feedstock, saidcontinuous wire feedstock, and said second continuous wire feedstock tosaid electromagnetic energy at said growth surface to form said meltpool on said growth surface, wherein said melt pool comprises at leastone of said powder feedstock in a molten form, said continuous wirefeedstock in a molten form, and said second continuous wire feedstock ina molten form, and wherein: said continuous wire feedstock has a firstdiameter; said second continuous wire feedstock has a second diameter;and said first diameter and said second diameter are different.
 2. Themethod of claim 1 further comprising adjusting a size of said melt pool.3. The method of claim 1 wherein: said deposition head comprises ahousing, wherein said housing comprises a sidewall that forms a nozzlebody, an upper end, an open interior, and an open lower end; andexposing at least one of said powder feedstock and said continuous wirefeedstock to said electromagnetic energy to form said melt poolcomprises: directing a laser beam through said open lower end of saidhousing to said growth surface from a laser, located within said openinterior of said housing; and irradiating at least one of said powderfeedstock and said continuous wire feedstock with said laser beam. 4.The method of claim 3 further comprises selectively positioning anoptic, located within said open interior of said housing, to focus saidlaser beam.
 5. The method of claim 4 further comprising linearly movingsaid optic relative to said laser, using an optic drive mechanism, toadjust a size of said melt pool.
 6. The method of claim 3 wherein:depositing said powder feedstock comprises passing said powder feedstockthrough said powder guide formed in said sidewall of said housing andextending from said upper end to said open lower end of said housing;and depositing said continuous wire feedstock comprises passing saidcontinuous wire feedstock through said wire guide formed in saidsidewall of said housing, separate from said powder guide, and extendingfrom said upper end to said open lower end of said housing.
 7. Themethod of claim 1 further comprising: supplying, at a selected firstfeed rate, said powder feedstock from a source of said powder feedstockto said deposition head using a powder delivery mechanism; andsupplying, at a selected second feed rate, said continuous wirefeedstock from a source of said continuous wire feedstock to saiddeposition head using a wire feedstock delivery mechanism.
 8. The methodof claim 1 wherein: said powder feedstock comprises a first constituentmaterial; said continuous wire feedstock comprises a second constituentmaterial; said second continuous wire feedstock comprises a thirdconstituent material; and at least any two of said first constituentmaterial, said second constituent material, and said third constituentmaterial are different.
 9. The method of claim 1 further comprising:depositing a second powder feedstock through a second powder guide ofsaid deposition head on said growth surface in a powdered form; andexposing at least one of said powder feedstock, said continuous wirefeedstock, and said second powder feedstock to said electromagneticenergy at said growth surface to form said melt pool on said growthsurface, wherein said melt pool comprises at least one of said powderfeedstock in a molten form, said continuous wire feedstock in a moltenform, and said second powder feedstock in a molten form.
 10. The methodof claim 9 wherein: said powder feedstock comprises a first constituentmaterial; said continuous wire feedstock comprises a second constituentmaterial; said second powder feedstock comprises a third constituentmaterial; and at least any two of said first constituent material, saidsecond constituent material, and said third constituent material aredifferent.
 11. The method of claim 1 wherein said laser comprises afiber laser.
 12. The method of claim 1 wherein said laser is a 5 kWfiber laser.
 13. A method for additively manufacturing athree-dimensional article, said method comprising: dispensing a powderfeedstock through a powder guide on a growth surface in a powdered form;dispensing a wire feedstock through a wire guide, which is separate fromsaid powder guide, on said growth surface in a solid form; directing alaser beam to said growth surface; irradiating at least one of saidpowder feedstock and said wire feedstock using said laser beam at saidgrowth surface to form a melt pool on said growth surface, wherein saidmelt pool comprises at least one of said powder feedstock in a moltenform and said continuous wire feedstock in a molten form; dispensing asecond wire feedstock through a second wire guide, which is separatefrom said powder guide and said wire guide, on said growth surface in asolid form; and irradiating at least one of said powder feedstock, saidwire feedstock, and said second wire feedstock using said laser beam,emitted by a laser, at said growth surface to form said melt pool onsaid growth surface, wherein said melt pool comprises at least one ofsaid powder feedstock in said molten form, said continuous wirefeedstock in said molten form, and said second continuous wire feedstockin a molten form, and wherein said wire feedstock and said second wirefeedstock have different diameters.
 14. The method of claim 13 furthercomprising focusing said laser beam to modify a size of said melt pool.15. The method of claim 13 wherein said powder feedstock and said wirefeedstock are compositionally different.
 16. The method of claim 13further comprising: dispensing a second powder feedstock through asecond powder guide, which is separate from said powder guide and saidwire guide, on said growth surface in a powdered form; and irradiatingat least one of said powder feedstock, said wire feedstock, and saidsecond powder feedstock using said laser beam at said growth surface toform said melt pool on said growth surface, wherein said melt poolcomprises at least one of said powder feedstock in said molten form,said continuous wire feedstock in said molten form, and said secondpowder feedstock in a molten form.
 17. The method of claim 16 wherein:said powder feedstock and said second powder feedstock arecompositionally different; and said wire feedstock is compositionallydifferent than at least one of said powder feedstock and said secondpowder feedstock.
 18. The method of claim 13 wherein: said wirefeedstock and said second wire feedstock are compositionally different;and said powder feedstock is compositionally different than at least oneof said wire feedstock and said second wire feedstock.
 19. The method ofclaim 13 wherein said laser comprises a fiber laser.
 20. The method ofclaim 13 said laser is a 5 kW fiber laser.